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Cardboard U-Shaped Routing Shield/Guide

There are certain instances when a wire harness, or some other flexible bundle, needs to be fed through a series of holes. As wire will bend when it hits the edge of a hole it makes it difficult to feed the harness from point A to point B in a timely manner. In this instance the wire harness must be fed through 5 holes which are not in a straight line or all the same size. See Figures 1 and 2. Due to time constraints in the assembly plant, an assembly aid was required for the operator to feed the harness through the holes to meet cycle time for their job.

Fig. 1 (Showing number of holes) Fig. 2 (Showing misaligned holes)

The initial thought was to use plastic for the shield as it needed to be rigid. There were three issues, the assembly plant did not have time to put the shield on the harness, the cost of the plastic shield was high, and the plant would have to throw away the shield. It was decided to make the shield out of cardboard. This way the shield can be recycled and it is four times less the cost of the plastic shield. To make the shield, see figure 3, you first fold up sides BG & CDEF. You then fold tab G inward then wrap D, E, and F around tab G to create the point. The point helps deflect the shield off of the sides of the holes allowing the harness to be fed through the holes quickly. You can secure tab F to the side of B with glue or in this instance wrapped in tape to keep it closed (see figure 4). Depending...